Flow Conditioner with Integral Vanes

ABSTRACT

A flow conditioner includes a single disk comprising an array of holes; a first set of integral vanes at least partially following a contour or pattern of an outer ring the holes; and a second set of integral vanes at least partially following a contour or pattern of an inner ring the holes. The second set of integral vanes is recessed from the first set of integral vanes in a stepped configuration.

This PCT international application claims priority to U.S. Ser. No. 61/753,547 filed on Jan. 17, 2013 in the U.S. Patent and Trademark Office, the entirety of which is incorporated herein by reference.

I. TECHNICAL FIELD

The present invention relates to fluid flow measurement components used in oil and gas pipelines. More particularly, the present invention relates to a flow conditioner having integral vanes.

II. BACKGROUND OF THE INVENTION

Pipelines are used to transport fluids in various industries, including chemical, oil and gas, and manufacturing. These industries use processes that require fluid flow rates to be accurately measured. These measurements are performed at locations known as meter stations using a variety of different meter types. These meters function in different ways, they can use: differential pressure of the fluid across an obstruction, ultrasonic signal travel times, turbine blade rotational speed, Coriolis forces, or even electrical and magnetic fields being generated due to bulk fluid movement. Almost all of these measurement methods require use of the fluid velocity distribution, known as a velocity flow profile.

To achieve the most accurate measurements, the flow profile of the fluid entering a metering device must be stable, non-rotating, and symmetric. This type of velocity distribution is known as a fully developed flow profile, and it forms naturally in very long lengths of uninterrupted straight pipe. However, having long lengths of straight pipe is impractical and cost prohibitive. As a result, meter station piping often contains elbows, tees, valves and other assemblies that distort the flow profile into an asymmetric, unstable, and distorted configuration. This makes it very difficult to measure the fluid flow rate in a consistently accurate and repeatable manner. Under these conditions, flow conditioners are needed to correct the flow profile of the fluid such that it forms a fully developed flow profile which allows accurate, repeatable measurements to be made.

Several types of flow conditioners exist, including straightening vanes, tube bundles, and perforated plates. These flow conditioners are placed within the pipe upstream of the flow meter. A typical perforated plate flow conditioner consists of a perforated metal plate that is arranged within a pipe orthogonal to the fluid flow, i.e., across the entire cross section of pipe. The perforations or holes in the flow conditioner cause the fluid flow to be redistributed such that it forms a fully developed flow profile. The placement of a flow conditioner upstream of the flow meter ensures that the flow is fully developed before it reaches the meter. This allows the meter to perform significantly more accurate and repeatable fluid flow measurements.

Currently, vanes or vane assemblies are welded onto flow conditioners or may comprise an assembly placed within a pipeline upstream of a flow conditioner. Due to the extreme forces in pipelines, such vanes typically fail, in particular where vanes are welded onto a flow conditioner plate. Thus, the vanes may be significantly damaged or broken into pieces, thereby damaging the pipeline and/or a downstream flow meter.

III. SUMMARY OF THE INVENTION

The invention provides in a first embodiment a flow conditioner characterized by a single disk comprising an array of holes; a first set of integral vanes at least partially following a contour or pattern of an outer ring the holes; and a second set of integral vanes at least partially following a contour or pattern of an inner ring the holes. The second set of integral vanes is recessed from the first set of integral vanes in a stepped configuration.

The invention provides in a second embodiment to any of the previous embodiments a flow conditioner characterized in that the first set of integral vanes extend from an outer ring of holes and the second set of integral vanes extend from an inner ring of holes.

The invention provides in a third embodiment to any of the previous embodiments a flow conditioner characterized in that the first set of integral vanes follows a contour of the outer ring of holes from a first surface of the flow conditioner to a surface of the second set of integral vanes.

The invention provides in a fourth embodiment to any of the previous embodiments a flow conditioner characterized in that the first and second set of integral vanes are on an upstream side of the flow conditioner.

The invention provides in a fifth embodiment to any of the previous embodiments a flow conditioner characterized in that the first and second set of integral vanes are on a downstream side of the flow conditioner.

The invention provides in a sixth embodiment to any of the previous embodiments a flow conditioner characterized in that the first and second set of integral vanes are on both sides of the flow conditioner.

The invention provides in a seventh embodiment to any of the previous embodiments a flow conditioner further characterized by a flange connection surrounding the single disk.

The invention in another embodiment provides a pipe assembly for flow measurement characterized by a fluid flow pipe; and a flow conditioner according to any of the previous embodiments disposed within the fluid flow pipe in an orientation substantially perpendicular to an axis of the fluid flow pipe.

The invention in a further embodiment provides a fluid flow measurement system characterized by a fluid flow pipe; a flow conditioner according to any of the previous embodiments disposed within the fluid flow pipe in an orientation substantially perpendicular to an axis of the fluid flow pipe; and a flow meter downstream of the flow conditioner.

As used herein “substantially”, “relatively”, “generally”, “about”, and “approximately” are relative modifiers intended to indicate permissible variation from the characteristic so modified. They are not intended to be limited to the absolute value or characteristic which it modifies but rather approaching or approximating such a physical or functional characteristic.

In the detailed description, references to “one embodiment”, “an embodiment”, or “in embodiments” mean that the feature being referred to is included in at least one embodiment of the invention. Moreover, separate references to “one embodiment”, “an embodiment”, or “in embodiments” do not necessarily refer to the same embodiment; however, neither are such embodiments mutually exclusive, unless so stated, and except as will be readily apparent to those skilled in the art. Thus, the invention can include any variety of combinations and/or integrations of the embodiments described herein.

Given the following enabling description of the drawings, the methods and systems should become evident to a person of ordinary skill in the art.

IV. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a flow conditioner having integral vanes following the contours of an outer ring of holes.

FIG. 2A illustrates a perspective view of a flow conditioner having a flange and integral vanes on an outer ring of holes on both sides of the flow conditioner.

FIG. 2B illustrates a front view of the flow conditioner of FIG. 2A.

FIG. 2C illustrates a cross sectional view of the flow conditioner of FIG. 2A.

FIG. 3A illustrates a rear perspective view of a flow conditioner having a flange flush with an end of the flow conditioner and integral vanes on a downstream side of the flow conditioner.

FIG. 3B illustrates a front view of the flow conditioner of FIG. 3A.

FIG. 3C illustrates a cross sectional view of the flow conditioner of FIG. 3A.

FIG. 4A illustrates a rear perspective view of flow conditioner having a flange and integral vanes on an upstream side of the flow conditioner.

FIG. 4B illustrates a front view of the flow conditioner of FIG. 4A.

FIG. 4C illustrates a cross sectional view of the flow conditioner of FIG. 4A.

FIG. 5 illustrates a cut-away partial view of a flow conditioner with integral vanes on an outer ring on an upstream side of the flow conditioner.

FIG. 6 illustrates a cut-away partial view of a flow conditioner with integral vanes on an outer ring on a downstream side of the flow conditioner.

FIG. 7 illustrates a cut-away partial view of a flow conditioner with integral vanes on an outer ring on both sides of the flow conditioner.

FIG. 8 illustrates a perspective view of a flow conditioner having integral vanes following the contours of an outer ring of holes and an inner ring of holes.

FIG. 9A illustrates a rear perspective view of a flow conditioner having a flange flush with an end of the flow conditioner and integral vanes on an outer ring and an inner ring on a downstream side of the flow conditioner.

FIG. 9B illustrates a front view of the flow conditioner of FIG. 9A.

FIG. 9C illustrates a cross sectional view of the flow conditioner of FIG. 9A.

FIG. 10 illustrates a cut-away partial view of a flow conditioner with integral vanes on an outer ring and an inner ring on an upstream side of the flow conditioner.

FIG. 11 illustrates a cut-away partial view of a flow conditioner with integral vanes on an outer ring and an inner ring on a downstream side of the flow conditioner.

FIG. 12 illustrates a cut-away partial view of a flow conditioner with integral vanes on an outer ring and an inner ring on both sides of the flow conditioner.

FIG. 13 illustrates a cut-away partial perspective view of a vane ring having vanes on an outer ring that can be applied to a flange of an existing flow conditioner to provide integral vanes.

FIG. 14A illustrates a rear perspective view of a flow conditioner having 1) a flange on a first side; 2) integral vanes on a first side at least partly following contours of an outer ring of holes or apertures; and 3) integral vanes on a first side at least partly following contours of an inner ring of holes or apertures according to another embodiment of the present invention.

FIG. 14B illustrates a front view of the flow conditioner of FIG. 14A.

FIG. 14C illustrates a cross sectional view of the flow conditioner of FIG. 14A.

FIG. 15A illustrates a rear perspective view of a flow conditioner having 1) a flange on a first side; 2) integral vanes on a second side at least partly following contours of an outer ring of holes or apertures; and 3) integral vanes on a second side at least partly following contours of an inner ring of holes or apertures according to another embodiment of the present invention.

FIG. 15B illustrates a front perspective view of the flow conditioner of FIG. 15A.

FIG. 16 is a graph showing a flow profile in a straight pipe with the flow conditioner of FIGS. 15A-B.

FIG. 17 is a graph showing a flow profile in an empty pipe, the fluid having 30 degrees of swirl.

FIG. 18 is a graph showing a flow profile of the flow profile with the flow conditioner of FIGS. 15A-B, the fluid having 30 degrees of swirl.

FIG. 19 is a graph showing the crossflow (swirl) significance with a flow conditioner of FIGS. 15A-B, the fluid having 30 degrees of swirl.

Given the following enabling description of the drawings, the methods and systems should become evident to a person of ordinary skill in the art.

V. DETAILED DESCRIPTION OF THE INVENTION

According to the present invention, a flow conditioner has at least one integral vane, for example a plurality of integral vanes, that is machined out of the same material as the flow conditioner itself. Thus, the at least one integral vane is physically part of the flow conditioner (e.g., physically machined out of the original flow conditioner). The at least one vane is not separately attached or connected to the flow conditioner, for example, via a weld or adhesive connection. The at least one integral vane does not extend radially on and/or linearly from a surface of a flow conditioner. The at least one integral vane reduces fluid swirl entering and/or leaving the flow conditioner, thereby improving flow conditioner performance without being torn or ripped from the flow conditioner due to pipeline forces.

The at least one integral vane at least partially follows a hole layout (e.g., the contours or pattern of the holes) of a flow conditioner. In a specific embodiment, the at least one integral vane may follow at least part of a hole pattern of an outer ring and/or inner ring of holes. The at least one integral vane may at least partly follow a hole contour or pattern of the flow conditioner, for example, from a first surface of the flow conditioner to a second surface of the flow conditioner.

As shown in FIG. 1, a flow conditioner 100 according an embodiment of the present invention may comprise a single disk 105 comprising a plurality of holes or apertures 110. A plurality of integral vanes 120 is machined out of the same material as the disk 105 and partially follows the contour or pattern of an outer ring of holes 115. Each integral vane 120 extends upward from between two outer holes 115, thereby defining a substantially flat inwardly-facing surface 125 and two curved sides 130, each curved side defined by and integral with part of the circumference of an outer hole 115.

An optional flange 135 may surround a flow conditioner according to the present invention, for example as illustrated in FIGS. 2A and 4A, or may be flush with an end (e.g., an upstream end/face or a downstream end/face) of the flow conditioner, for example as illustrated in FIGS. 3A and 9A. The flange may provide a connection to a pipe within which the flow conditioner is installed.

According to a specific embodiment of the present invention, a plurality of integral vanes 120 may be on both sides of a flow conditioner, as illustrated in FIGS. 2A-2C and FIG. 7. Alternatively, a plurality of integral vanes 120 may be on a downstream side of a flow conditioner, as illustrated in FIGS. 3A-3C and FIG. 6, or may be on an upstream side of a flow conditioner, as illustrated in FIGS. 4A-4C and FIG. 5.

According to a specific embodiment of the present invention, as shown in FIG. 8, a flow conditioner 200 may comprise a single disk 205 comprising a plurality of holes or apertures 210, and having a plurality of integral vanes 215 a, 215 b that are machined out of the same material as the disk. One set of integral vanes 215 a follows at least part of the hole contour or pattern of an outer ring of holes. In addition, another set of integral vanes 215 b follows the hole contour or pattern of an inner ring of holes.

Each integral vane 215 b on the inner ring of holes extends upward between two holes, thereby having 1) a first substantially inner flat surface 220 and an opposing second curved surface 225, and 2) two curved sides 230 defined by and integral with part of the circumference of a hole on either side. Each integral vane 215 a on the outer ring of holes may have a configuration as discussed above with respect to FIG. 1.

According to the present invention, the plurality of integral vanes 215 a, 215 b may be on a downstream side of a flow conditioner, as illustrated in FIGS. 9A-9C and FIG. 11; on an upstream side of a flow conditioner, as illustrated in FIG. 10; or on both sides of a flow conditioner, as illustrated in FIG. 12.

According to another embodiment of the present invention, as illustrated in FIG. 13, a flow conditioner may comprise a vane ring 300. The vane ring 300 may be a separate element that may be used by itself in a pipeline or may be applied to or fit on an existing flow conditioner. A vane ring 300, for example, may comprise a plurality of outer vanes 305 along a contour or pattern of outer holes 310, with everything else corresponding to the flow conditioner drilled out. The vane ring 300 may be installed in an upstream or downstream configuration, either by itself or with an existing flow conditioner.

The vane ring 300 may have a flange. In a specific embodiment, the vane ring 300 may be clamped on or into a flange of an existing flow conditioner and sit immediately upstream of a flow conditioner plate. The flange closing pressure will hold the vane ring onto the flow conditioner, without the need for any weld or adhesive connection.

As shown in FIGS. 14A-14C, a flow conditioner 400 according to another embodiment of the present invention may comprise a single disk 405 comprising a plurality of holes or apertures 410, and having integral vanes 420 that are machined out of the same material as the disk. A first set of integral vanes 420 a follows at least part of the hole contour or pattern of an outer ring of holes, similar to FIG. 1. A second set of integral vanes 420 b similar to the first set 420 a follows the hole contour or pattern of an inner ring of holes, but is recessed from the first set of integral vanes 420 a (i.e., a stepped vane configuration). The integral vanes may be on a downstream side of a flow conditioner, on an upstream side of a flow conditioner, or on both sides of a flow conditioner.

The flange connection 425 shown in FIGS. 14B-14C is optional. The optional flange connection 425 may surround the flow conditioner or may be flush with an end (e.g., an upstream end/face or a downstream end/face) of the flow conditioner. As shown in FIGS. 15A-15B, the optional flange 425 may be on an opposite side than that shown in FIGS. 14A-140.

FIG. 16 is a graph showing a flow profile in a straight pipe with the flow conditioner of FIGS. 14A-C. All runs were done with natural gas as the fluid and with a 5 MPa outlet pressure. For a fluid having an initial fluid velocity of 25 m/s, FIG. 16 shows the fluid flow profiles measured horizontally (along a longitudinal axis of the length of the pipe in which the flow conditioner is installed) and vertically (along a transverse or perpendicular axis of the pipe) at distances downstream of the flow conditioner (i.e., 5D, 8D, and 15D, measured in inside or internal pipe diameters). The vertical axis of the graph is the measured velocity in m/s and the horizontal axis of the graph is the diameter across a pipe (i.e., 0.00 is the center of the pipe having an approximately 12 inch cross section).

As shown in FIG. 16, the flow profile has a fully developed form at each measured distance (5D, 8D, and 15D) and the illustrated flow lines substantially overlap.

FIG. 17 is a graph showing a flow profile in an empty pipe, the fluid having 30 degrees of swirl.

FIG. 18 is a graph showing a flow profile of the flow conditioner of FIGS. 15A-B, the fluid having 30 degrees of swirl. Measurements were taken as described above with respect to FIG. 16. The flow profile has a fully developed form at each measured distance (5D, 8D, and 15D) and the illustrated flow lines substantially overlap.

FIG. 19 is a graph showing the crossflow (swirl) significance with a flow conditioner of FIGS. 15A-B, the fluid having 30 degrees of swirl. The vertical axis is the swirl/crossflow significance (measured as a percentage of axial velocity) and the horizontal axis is the distance from the flow conditioner (measured in inside pipe diameters). As shown in FIG. 19, the swirl/crossflow significance substantially drops downstream of the flow conditioner, which is installed at zero.

Suitable flow conditioners with which to incorporate integral vanes may include, but are not limited to, CPA TBR and CPA 50E flow conditioners available from Canada Pipeline Accessories of Calgary, Alberta Canada; and the flow conditioners described in U.S. Pat. No. 5,341,848, which is herein incorporated by reference in its entirety.

In specific embodiments, the flow conditioner may be sized to pipe inside diameter D (0.85D-0.99D). In specific embodiments, the flow conditioner thickness may be about 0.05D-0.35D. In specific embodiments, the vane length may be about 0.10D-5.25D. In specific embodiments, an outer ring of vanes may end at between 0.70D-0.95D and an inner ring of vanes may be between about 0.35D to 0.65D.

The flow conditioner according to the present invention may be utilized in existing piping without making modifications. In specific embodiments, the flow conditioner may have a flanged connection, which is frequently available in meter stations. Thus, it is very simple and extremely compatible with meter station layouts.

VI. INDUSTRIAL APPLICABILITY

The present invention relates to a flow conditioner having at least one integral vane, for example, a plurality of integral vanes. The integral vanes reduce fluid swirl entering and/or leaving the flow conditioner, thereby improving flow conditioner performance without tearing or ripping the integral vane from the flow conditioner due to pipeline forces.

Although the present invention has been described in terms of particular exemplary and alternative embodiments, it is not limited to those embodiments. Alternative embodiments, examples, and modifications which would still be encompassed by the invention may be made by those skilled in the art, particularly in light of the foregoing teachings.

Those skilled in the art will appreciate that various adaptations and modifications of the exemplary and alternative embodiments described above can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. 

1. A flow conditioner, comprising: a single disk comprising an array of holes; a first set of integral vanes at least partially following a contour or pattern of an outer ring the holes, and a second set of integral vanes at least partially following a contour or pattern of an inner ring the holes, wherein the second set of integral vanes is recessed from the first set of integral vanes in a stepped configuration.
 2. A flow conditioner according to claim 1, wherein the first set of integral vanes extend from an outer ring of holes and the second set of integral vanes extend from an inner ring of holes.
 3. A flow conditioner according to claim 1, wherein the first set of integral vanes follows a contour of the outer ring of holes from a first surface of the flow conditioner to a surface of the second set of integral vanes.
 4. A flow conditioner according to claim 1, wherein the first and second set of integral vanes are on an upstream side of the flow conditioner.
 5. A flow conditioner according to claim 1, wherein the first and second set of integral vanes are on a downstream side of the flow conditioner.
 6. A flow conditioner according to claim 1, wherein the first and second set of integral vanes are on both sides of the flow conditioner.
 7. A flow conditioner according to claim 1, further comprising a flange connection surrounding the single disk.
 8. A pipe assembly for flow measurement, comprising: a fluid flow pipe; a flow conditioner according to claim 1 disposed within said fluid flow pipe in an orientation substantially perpendicular to an axis of said fluid flow pipe.
 9. A fluid flow measurement system, comprising: a fluid flow pipe; a flow conditioner according to claim 1 disposed within said fluid flow pipe in an orientation substantially perpendicular to an axis of said fluid flow pipe; and a flow meter downstream of the flow conditioner.
 10. A flow conditioner, comprising: a single disk comprising an array of holes; a first set of integral vanes at least partially following a contour or pattern of an outer ring the holes, each integral vane defined by a substantially flat inwardly-facing surface between two outer holes and two curved sides, each curved side defined by and integral with part of the circumference of an outer hole; and a second set of integral vanes at least partially following a contour or pattern of an inner ring the holes, each integral vane defined by a substantially flat inwardly-facing surface between two inner holes and two curved sides, each curved side defined by and integral with part of the circumference of an inner hole, wherein the second set of integral vanes is recessed from the first set of integral vanes in a stepped configuration. 